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http://www.openelectrical.org/wiki/index.php?title=Load_Schedule
Introduction
Calculation Methodology
There are no standards governing load schedules and therefore this calculation is based
on generally accepted industry practice. The following methodology assumes that the
load schedule is being created for the first time and is also biased towards industrial
plants. The basic steps for creating a load schedule are:
Step 5: For each switchboard and the overall system, calculate operating,
peak and design load
Process loads - are the loads that are directly relevant to the facility. In
factories and industrial plants, process loads are the motors, heaters,
compressors, conveyors, etc that form the main business of the plant.
Process loads can normally be found on either Mechanical Equipment
Lists or Process and Instrumentation Diagrams (P&ID's).
Non-process loads - are the auxiliary loads that are necessary to run the
facility, e.g. lighting, HVAC, utility systems (power and water),
DCS/PLC control systems, fire safety systems, etc. These loads are
usually taken from a number of sources, for example HVAC engineers,
instruments, telecoms and control systems engineers, safety engineers,
etc. Some loads such as lighting, UPS, power generation auxiliaries, etc
need to be estimated by the electrical engineer.
Rated power is the full load or nameplate rating of the load and
represents the maximum continuous power output of the load. For motor
loads, the rated power corresponds to the standard motor size (e.g. 11kW,
37kW, 75kW, etc). For load items that contain sub-loads (e.g. distribution
boards, package equipment, etc), the rated power is typically the
maximum power output of the item (i.e. with all its sub-loads in service).
Absorbed power is the expected power that will be drawn by the load.
Most loads will not operate at its rated capacity, but at a lower point. For
example, absorbed motor loads are based on the mechanical power input
to the shaft of the driven equipment at its duty point. The motor is
typically sized so that the rated capacity of the motor exceeds the
expected absorbed load by some conservative design margin. Where
information regarding the absorbed loads is not available, then a load
factor of between 0.8 and 0.9 is normally applied.
load is used, but the power factor at the duty point can also be used for
increased accuracy. Where power factors are not readily available, then
estimates can be used (typically 0.85 for motor loads >7.5kW, 1.0 for
heater loads and 0.8 for all other loads).
1) Normal loads are those that run under normal operating conditions, e.g. main
process loads, normal lighting and small power, ordinary office and workshop
loads, etc
2) Essential loads are those necessary under emergency conditions, when the
main power supply is disconnected and the system is being supported by an
emergency generator, e.g. emergency lighting, key process loads that operate
during emergency conditions, fire and safety systems, etc
3) Critical are those critical for the operation of safety systems and for
facilitating or assisting evacuation from the plant, and would normally be
supplied from a UPS or battery system, e.g. safety-critical shutdown systems,
escape lighting, etc
Where
Notice that the loads have been categorised into three columns depending on their load
duty (continuous, intermittent or standby). This is done in order to make it visually
easier to see the load duty and more importantly, to make it easier to sum the loads
according to their duty (e.g. sum of all continuous loads), which is necessary to
calculate the operating, peak and design loads.
Where
Peak load
The peak load is the expected maximum load during normal operation. Peak loading is
typically infrequent and of short duration, occurring when standby loads are operated
(e.g. for changeover of redundant machines, testing of safety equipment, etc). The peak
load is calculated as the larger of either:
or
Where
Design load
The design load is the load to be used for the design for equipment sizing, electrical
studies, etc. The design load is generically calculated as the larger of either:
or
Where
Worked Example
Step 1: Collect list of loads
Consider a small facility with the following loads identified:
Eff.
750kW
800kW
0.87 0.95
750kW
800kW
0.87 0.95
Recirculation pump A
31kW
37kW
0.83 0.86
Recirculation pump B
31kW
37kW
0.83 0.86
Sump pump
9kW
11kW
0.81 0.83
Firewater pump A
65kW
75kW
0.88 0.88
Firewater pump B
65kW
75kW
0.88 0.88
HVAC unit
80kW
90kW
0.85 0.9
AC UPS System
9kW
12kW
0.85 0.9
7kW
10kW
0.8
0.9
4kW
5kW
0.8
0.9
Duty
Criticality
800kW
6.6kV
Continuous
Normal
800kW
6.6kV
Standby
Normal
Recirculation pump A
37kW
415V
Continuous
Normal
Recirculation pump B
37kW
415V
Standby
Normal
Sump pump
11kW
415V
Intermittent
Normal
Firewater pump A
75kW
415V
Standby
Essential
Firewater pump B
75kW
415V
Standby
Essential
HVAC unit
90kW
415V
Continuous
Normal
AC UPS System
12kW
415V
Continuous
Critical
10kW
415V
Continuous
Normal
5kW
415V
Continuous
Essential
Intermittent
Standby
P
Q
(kW) (kVAr)
P
Q
(kW) (kVAr)
P
Q
(kW) (kVAr)
Load
Description
Abs
Load
Vapour
recovery
compressor A
Vapour
PF
Eff.
447.4
789.5
447.4
recovery
compressor B
Recirculation
pump A
31kW
Recirculation
pump B
31kW
0.83 0.86
Sump pump
9kW
Firewater
pump A
24.2
36.0
24.2
0.81 0.83
10.8
7.9
65kW
0.88 0.88
73.9
39.9
Firewater
pump B
65kW
0.88 0.88
73.9
39.9
HVAC unit
80kW
0.85 0.9
88.9
55.1
AC UPS
System
9kW
0.85 0.9
10.0
6.2
Normal
lighting
distribution
board
7kW
0.8
0.9
7.8
5.8
Essential
lighting
distribution
board
4kW
0.8
0.9
4.4
3.3
936.6
542.0
10.8
7.9
973.3
551.4
SUM TOTAL
936.6
542.0
5.4
4.0
97.3
55.1
789.5
447.4
Operating load
942
546.0
Peak load
1,731.5
993.4
Design load
1,825.7 1,047.9
Normally you would separate the loads by switchboard and calculate operating, peak
and design loads for each switchboard and one for the overall system. However for the
sake of simplicity, the loads in this example are all lumped together and only one set of
operating, peak and design loads are calculated.